Terminal wiring apparatus



May l, 1951 Original Filed K. H. ANDREN 2,551,358

TERMINAL WIRING APPARATUS' Dec. 19. 1942 12 Sheets-Sheet l A TTO RNEYQS.

May 1 1951 K. Hl ANDREN 2,551,358

TERMINAL WIRING APPARATUS Original Filed Dec. 19, 1942 12 Sheets-Sheet 21 58 Air-' 141 .l l 127" "H f /09 e .sz

ATTORNEYCS.

May l 1951 K. H. ANDREN 2,551,358

TERMINAL WIRING APPARATUS Original Filed Dec. 19, 1942 12 Sheets-Sheet 3:Smit-5:5556

LK--- J ATTORNEYQS May 1, l951 K. H. ANDREN 2,551,358

TERMINAL WIRING APPARATUS Original Filed Dec. 19, 1942 12 Sheets-Sheet 4cama ng.

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CA H (L Mauve msu) A TTORNEYS May l, 1951 K. H. ANDREN TERMINAL WIRINGAPPARATUS Original Filed Dec. 19, 1942 12 Sheets-Sheet 5 ATTOR NEY.

12 Sheets-Sheet 6 K. H. ANDREN TERMINAL WIRING APPARATUS Original FiledDec. 19, 1942 May l, 1951 A T TOR NEY.

May l, 1951 K. H. ANDREN TERMINAL WIRING APPARATUS All w l 4 OriginalFiled Dec. 19, 1942 May l 1951 K. H. ANDREN 2,551,358

TERMINAL WIRING APPARATUS Original Filed Dec. 19, 1942 12 Sheets-Sheet 8BY l May l, 1951 K. H. ANDREN TERMINAL WIRING APPARATUS 12 Sheets-Sheet9 Original Filed Dec. 19, 1942 ,Ej/19.20. Eliza May l, 1951 K. H. ANDRENTERMINAL WIRING APPARATUS Original Filed Deo. 19. 1942 12 Sheets-Sheet11 f ArroRNEs/.

May l, 1951 K. H. ANDREN 2,551,358

TERMINAL WIRING APPARATUS Original Filed Dec. 19, 1942 12 Sheets-Sheetl2 as n Q Q H TTOENE Y.

Planted May i, los! TERMINAL WIRING APPARATUS mi n. snaren. GII-Sensus,wis.. mignon, by

menne assignments, to Western Electric Company, Incorporated, New York,N. Y., a corporation of New York Continuation oi' application Serial No.469,526, December ill, 1942. This application February 10, 1949, SerialNo. 75,731

18 Claims. (Cl. 2H!) This invention relates generally to improvements inthe art of assembling a succession of relatively irregular but similarelements in predetermined order with a series of elongated members, andrelates more speciiically to an improved method of and apparatus forattaching successive groups of terminals to a plurality of sets ofelectrical conductors or wires. and to a new mode of combining theassemblages in stacks or banks. and this application is a continuationof my copending application. Serial No. 469,526, filed December 19,1942, and now forfeited.

The primary object of this invention is to provide a new and usefulmethod of and apparatus for expediting the attachment of successivesimilar elements such as groups or layers of telephone circuitterminals, to a plurality of elongated members, such as insulatedcurrent conducting wires, so that the assembled elements and members maybe readily applied to and utilized in nal assemblages such as telephonesystems.

It has heretofore been common practice in the art of constructing andinstalling automatic telephone systems, to utilize numerous so-calledterminal banks each consisting of a stack of terminal cards each in turncomprising two arcuate groups or flat layers of terminals separated byan arcuate sheet of insulation, these terminal banks being finallyinstalled laterally adjacent to each other and having the correspondingterminals thereof connected ln series by insulated conductor wires. Thesuccessive banks of terminal cards were heretofore assembled in stacksbefore the individual conductor wires were attached to the correspondingterminals thereof; and in order to effect such attachment, it wasnecessary to remove the insulation locally from each wire and to solderthe bared portion of each wire to the proper terminal of each bank.Since each of these terminal banks measured only about four inches inlength by one and one-half inches in width by one and one-quarter inchesin height, and embodies approximately ten of the terminal cards eachhaving twenty terminal connections, which, in the completed assemblages,are located only one-eighth of an inch apart, it must be apparent thatthe job of soldering a wire to each of these connections, as by the oldmethod, was indeed very tedious, slow and costly, especially in view ofthe fact that thousands of the bank assemblages are required. In orderto reduce electrical disturbances to a minimum, it is also desirable totwist each complementary pair of insulated conductor wires about eachother on the opposite sides of each zone of attachment of the wires tothe successive terminals, and it was extremely difllcult, with theprevious method of soldered attachment, to eil'ect such twisting withoutdisrupting the solder Joints. These soldered connections of the priorassemblages were also relatively weak and subject to breakage due tohandling and Jolting, thus causing considerable trouble and annoyanceand interfering' with proper functioning of the allied apparatus. But inspite of all of these diiilculties and disadvantages, the prior mode ofproducing and of assembling such terminal systems has been universallyfollowed, primarily for want of a better substitute method ofproduction.

It is, therefore, a more specinc object of my present invention toprovide an improved method cf electrically interconnecting and ofassembling such standard terminal layers, cards and banks in telephonesystems in an expeditious manner and with vastly improved results.

Another specific object of the present invention is to provide a newmethod of more effectively wiring these telephone terminal banks withoutlocal removal of the insulation, without resorting to soldering, andwithout necessity of spreading arxlid undesirably bending the terminalsout of s ape.

A further specic object of this invention is to provide an improved modeof attaching the conductors to terminal cards, and of twisting tliocomplementary pairs of wires about each other on opposite sides of eachzone of attachment, in a durable and methodical manner, and with theminimum manual labor, thereby producing superior assemblages at greatlyreduced cost.

Still another specific object of my invention is to provide a new systemof automatically and mechanically assembling the terminal layers andconductors of telephone control equipment, in a most reliable andaccurate manner, at far greater speed than was heretofore possible, andso that the successive bank units will all be identical in structure.

An additional specific object of the invention is to provide variousimprovements in the construction and operation of apparatus forfacilitating automatic exploitation of the improved terminal wiring andassembly method in an expedltious and methodical manner, and at minimumcost and maximum speed.

These and other specific objects and advantages of the presentimprovement will be apparent from the following detailed description.

A clear conception ci' the several steps of my improved method. and ofthe construction and operation of one type of apparatus for effectingautomatic and commercial exploitation of the new method, may be had byreferring to the drawings accompanying and forming a part of thisspecification wherein like reference charactersdeaignate the sameorsimilarpartsinthe various views.

Fig. 1 is a front and side perspective view of a machine for carrying onmy improved method of wiring telephone terminal assemblages, as itappears during normal operation;

Fig. 2 is a somewhat enlarged fragmentary similar perspective view ofthe terminal attaching punch and die assemblage of the machine, showingthe terminal card supplying table swung out of normal position and awayfrom the die mechanism so as to permit free access to the latter;

Fig. 3 is a further enlarged rear and side perspective view of afragment of the improved machine. showing a portion of the punch and dieand the spinning mechanism for twisting the complementary pairs ofconductor wires about each other on the opposite sides of `successivespread sones thereof;

Fig. 4 is a somewhat smaller fragmentary rear perspective view of thewire feeding and spinning or twisting mechanism. also showing the wireadvancing slides for periodically feeding the successive locally spreadand twisted wire portions toward the clamping punch and die; i

Fig. 5 is a horizontal section through the improved machine takenbetween the punch and die and showing several of the wire spinningor/.f

twisting rotors in section;

Fig. 6 is a chart showing the timing and sequence of the severalsuccessive steps of the improved wiring method as carried on by theimproved automatic machine;

Fig. I is a central horizontal section through the main gear box andcams for producing properly timed operation of the several mechanisms soas to methodically carry on the successive Fig. 8 is a central verticalsection through the main gear box and cam mechanisms of Fig. '1, showingsome of the cams in dot-and-dash lines for the sake of clearness;

Fig. 9 is apart sectional elevation of the gear box and driving camassemblage, looking toward the left end of Fig. B;

Fig. 10 is an enlarged fragmentary vertical section through the activeassembly portion of the machine, showing the punch in lowered positionand coacting with the die, the wire separating and spinning mechanism,and the wire clamping and advancing mechanism, the wire spreader beingshown in lowered position and the pick up fingers coacting with the pushand die;

Fig. l1 is a transverse vertical section through the complementary wireadvancing slides showing the driving pinion coacting with the rack teethof one of these slides;

Fig. 12 is a front view of one of the wire holding clamps for limitingthe spinning or twisting action between successive sones of attachmentof the terminals to the wires;

Fig. 13 is a part sectional front view of one of the wire spinning ortwisting rotors and of the clamps coacting with the pivoted guidefingers thereof to properly position the twisted or spun pairs of wiresupon the adjacent spreader wedge;

Fig. i4 is an irregular vertical section through the frame and throughthe punch and die mechanism for clamping the terminals to the wires.

showing the punch and die separated or spread apart:

Fig. l5 is a vertical section through the separated punch and diemechanism. similar to that of Fig. i4 but enlarged sumciently to showthe action of the strippe Fig. i6 is a sectional view of one of thespinning rotors, spreader and clamps similar to Fig. 10, but showing theclamps in action and the intervening spreader elevated;

Fig. 17 is a fragmentary top view showing several of the wire spinningrotors,v clamps and spreaders, and also showing fragments of several ofthe wire advancing slides coacting with a terminal card:

Fig. 18 is a horizontal section through several of the terminal clampingpunches and through one of the ve slide operating shafts, looking downupon fragments of a number of the wire advancing slides and the guides;

Fig. 19 is an enlarged front elevation of one of the upper punches;

Fig. 20 is a similarly enlarged irregular vertical section through thepunch of Fig. i9, taken along the line 2li-20;

Fig. 21 is a similarLv enlarged front elevation of one of the lowerdies;

Fig. 22 is a sideelevation of the die of Fig. 2l;

Fig. 23 is a transverse section through the punch of Figs. i9 and 20.taken along the line 23-25;

Fig. 24 is a top view of the lower die:

Fig. 25 is a greatly enlarged fragment of a cooperating set of punchesand dies;

Fig. 26 is a plan view of a typical terminal card assemblage;

Fig. 2'? is a central vertical section through the card feed or supplytable and through the final assembly discharge conveyor;

Fig. 28 is a part sectional fragmentary top view of the card supplytable with the final discharge conveyor removed therefrom; and

Figs. 29 to 35, inclusive, are diagrams showing the successive steps ofthe improved method.

While the invention has been upon and described herein as beingespecially applicable for the purpose of attaching the correspondingterminals of successive similar arcuate groups to the same wires of alongitudinally advancing series without locally removing the insulationfrom the wires, and for twisting the complementary pairs of wires onopposite sides of each zone of attachment, it is not my desire or intentto thereby unnecessarily restrict the scope of the invention or theutility of the several features constitilting the present improvement.These features, and particularly the steps of the improved method, maybe advantageously utilized in conjunction with the production of otherassemblages, and the term "layer as used herein as applied to theterminals, is intended to include any pre-arranged relatively fiat groupof terminals or the like whether radially or otherwise disposed; whilethe term card" is intended to include several coacting layers or groupsof terminals usually separated by a layer of insulation but adapted tobe handled as a unit; and the term bank includes a stack of two or morecards which are definitely positioned with respect to each other, andare likewise adapted to be handled as a unit.

In accordance with a practical embodiment of my present improved methodof and apparatus for electrically connecting a plurality of terminalbanks so that each terminal of each bank is con- :,ssnsse nected by thesame wire in series with the same or corresponding terminals ofsuccessive prearranged banks. a multiplicity of insulated wires are nrstreceived or withdrawn from independent sources of supply and arearranged in complementary pairs which are intermittently andlongitudinally advanced along dennite paths leading radially toward acommon point or axis. successive sones of each complementary pair ofwires. are then spaced apart, and the two wires of each pair are spun ortwisted about each other on the opposite sides of each zone ofseparation. The successive spread zones of the pairs of wires aresubsequently advanced and positioned adjacent to the terminals ofarcuate groups or layers disposed adjacent to the point or axis towardwhich the wires are intermittently advanced, after which all of theterminals of each group are clamped to the proper wires while the latterare at rest, so as to produce electrical connections through theinsulation and the zones of separation. The wires are thenintermittently advanced longitudinally and approximately parallel toeach other, and the same wires are always connected to the correspondingterminals of each of the successive layers and cards of the series. Whena suillcient number of groups or cards have been thus attached to theadvancing wires, the wires are cut into proper lengths, and the cardsare assembled in properly and finally arranged stacks, whereupon thecorresponding terminals of the banks will be electrically connected inseries, and are ready for most effective cooperation with the brushes ofthe telephone system. In view of the fact that each card normally hastwenty terminals disposed closely adlacent to each other and each ofwhich must be electrically connected to an independent relatively ilneinsulated wire, the apparatus for automatically, effectively and rapidlyspinning the complementary pairs of wires, and for feeding andinterconnecting the wires and terminals, necessarily becomes quitecomplex, but such apparatus has been built and has proven highlysatisfactory in carrying on the improved method.

Referring to the drawings, one type of improved apparatus for carryingon a commercial exploitation of the improved method, is a machinecomprising a main stationary frame 26 having a plurality oi.'independent insulated wire supply reels 26 mounted rearwardly thereof,and a card feeding table 21 and an assembly discharge conveyor 2lpivotaliy suspended from the forward portion thereof; while the lowerpart of the frame provide a housing for operating mechanism driven by asuitable motor 29, and the upper portion of the frame provides a supportfor the wire spinning and feeding mechanism and for the attachingpunches at and dies 3l, see Fig. l. The main frame 25 may be durablyconstructed in any suitable manner as by utilizing sturdy welded plates,and while there is nothing special about the wire supply reels 26 andtheir mounting, there should be at least twenty of these reels some ofwhich should preferably carry wire 32 having insulation of differentexternal coloring from that of the other wires. Each of these reelsshould be provided with guide means for directing the wire 32 deliveredtherefrom toward a common point or axis disposed near the central frontportion of the frame 25. In order to insure proper guiding of theindividual insulated wires l2 from the supply reels 20 toward the fixedaxial point, a series of sets of guiding and tensioning wheels l! areprovided. as clearly shown in Figs.

8,4and5,andeachoftbesesetsofwheelsisadaptedtocoactwithaselectedpairofwires $2 having differently coloredinsulation.

From the guide wheels Il, each complementary pair of wires l2 extendsinto the rear end of a spinning or twisting rotor 34 iournalled forrotation within a housing 3l secured to the main frame 2l, and thecentral axes of rotation of all df the rotors Il are disposed radiallywith respect to nxed central point or vertical axis of the machine, seeFigs 8, 4, 5 and 10. Upon emerging from the front ends of the spinningrotors Il, i

the pairs of wires l2 extend past vertically movable spreaders 3l andbetween clamps 31 toward the corresponding punches ll and dies Il. andeach of the rotors N is provided with a set of swingably suspended wireguiding fingers Il with which another set of clamps I9 is cooperable inorder to insure proper cooperation of the adiacent spreader 86 with thewires 32, see Figs. 5, i0, 12 and 13. There is a set of cooperatingpunches )d and dies li for attaching each complementary pair of wires 32to the corresponding terminals of the successive terminal cards Il whenthese cards have been delivered in succession into the zone of action ofthe punches and dies, and after the successive equally spaced spreadzones of the pairs of wires 82 have been advanced into such zone ofaction of the attaching elements, so that ten independent sets ofpunches Il and dies Il should be provided if ten pairs of wires l2 areto be simultaneously attached to successive cards lil each having twentycorresponding terminals. The cards It are adapted to be fed laterallyand successively into the sone of action of the punches In and dies Il,by the table 21, and the spun and locally spread pairs of wires l2 areadapted to be advanced toward these zones by means of reciprocableslides 4i having sets of feed lingers 42, I2 adapted to pick thesuccessive spread portions of the wires `from the spreaders 36, whilethe conveyor 2l functions to deliver the assembled wires I2 and cards I0from the attaching zone across the top of the table 21, see Figs. i and10.

With the machine specifically shown, each complete cycle during whichthe wires I2 are spun and advanced and the card Ill is attached,consumes three seconds, and the sequence of operations and thefunctioning of the mechanism for performing the several successivesteps, can perhaps .be most readily understood by referring to the chartof Pig. 6, and to the details of the operating mechanism shown in Figs.7, 8 and 9. The driving source or motor 29 may be connected by means ofbelting Il and suitable pulleys, to a main horizontal drive shaft 45journalled in a housing forming part of the main frame 28, and thisshaft 4l carries a worm and has a front end extension 41 for driving thecard feed and the nnal discharge conveyor 2l as will be later explained.The worm le meshes with a worm wheel I! secured to a counter shaft l!which is also journalled in the frame housing, and this counter shaft lecarries cams A, B. C, D. E. F. G and also carries a bevel pinion ilmeshing with a bevel gear El mounted upon another counter shaft 52 whichcarries additional cams H, Lso that rotation of the drive shaft 45 bythe motor 2! will result in simultaneous rotation of all of the cams.From the chart, it will be apparent that the cam A horizontallyreciprocates the wire advancing or feed slides Il; the cam B actuates avertically reciprocable platen 7s 53 which carries the slides Il withtheir feed lingers 42, 43 the cam C actuates the spinner ngers 33 byoperating the clamps 39; the cam D actuates the separatingingers orspreads 3B. the cam E actuates the wire clamping fingers or clamps 31;the cams F and G actuate the punches 30 and dies 3|; and the cams H andI actuate the spinners or wire twisting rotors 34.

The groove cam A coacts with a roller a' carried by the swinging end ofa lever 55 which is freely swingably suspended from a horizontal countershaft 56 and also carries a roller coacting with a slotted rack 53', seeFigs. 5 and 8. A double rack 51 slidably mounted upon the upper platenIl is horizontally reciprocable by an upright drive shalt 53 having alower pinion Il' coacting with the rack 5B' and an upper pinion I3coacting with the teeth on the rear side of the rack l1, see Figs. 4, 'Iand 10. Because of the fact that the platen 53 is vertically movablerelative to the main frame 25, the driving connection between the shaft53 and the lower pinion must be splined so as to permit desired periodicvertical reclprocation of the platen 53. The reciprocable double rack 61has teeth on both sides, the front set of which is cooperable with twodriven pinions Bll carried by the upper ends of upright counter shafts3l, and the rear set oi which is likewise cooperable with three pinlcns3|! and counter shafts 6i. The lower ends of the counter shafts Si aresecured to pinions 32 which coact with rack teeth B3 formed on theslides 4l, and in order to permit the use oi' only ve counter shafts 6Ifor the purpose of reciprocating ten wire feeding slides 4i, each of thepinions 32 is caused to ccact with an idler pinion 64 which cooperateswith the teeth 63 on an adjacent slide 4l as illustrated in Fig. 18. Thecam A is therefore constructed and mechanically connected to the slides4| in such manner that continued rotation of the cam A will producesimultaneous periodic inward and outward movement of the ten slides 4Iradially of the central vertical axis of the machine, and the timing ofthese reciprocations is clearly indicated upon the chart of Fig. 6.

The groove cam B which slides the platen 53 up and down so as to permitproper cooperation of the feed ngers 42, t3 with the wires 32, coactswith a roller b' carried by the swinging end of a lever 65 which iskeyed to one end of the shaft 53, and a similar lever 66 is keyed to theopposite end of this shaft. The swinging end of the lever 86 isconnected by means of links 6l with an upper lever 63, shaft 54 andlever B3', pivotally suspended from the upper portion of the main frame25, as shown in Fig. 3, and which lever Gil is connected to the platen53 by means of an intermediate link 69 coacting with ears 13 formed onthe platen 53, see Figs. 3 and 4. This mechanical connection between thelever 65 and the platen 53 is such that the continued rotation of thecam B will periodically slide the Aplaten 53 up and down at properlytimed intervals. The slides 4I are mounted for radial reciprocationwithin guides G5', as clearly shown in Fig. 18, and the platen 53 andthe slides 4I and guides B5', which are carried thereby, are `preferablymounted so as to swing as a unit about a pivot Il disposed at one sideof the frame 25, so that the slide and platen assemblage may be swungout of normal position and will permit free access to the wire advancingiingers 42. 43, as clearly shown in the perspective view of Fig. 3. Thetiming of the up and down movement of the 8 platen 33 is also clearlyindicated upon the chart of Fig.

The groove cam C. which is adapted to actuate the spinner lingers 33 byoperating the clamps 39, one oiiwhich is associated with each set of thelingers 33, coacts with a roller c' carried by a lever 'I2 secured to a.pivot shaft 13, see Figs. 8, 9 and 10. A pair oi' levers 14 are alsosecured to the pivot shaft 13 and are pivotally connected to the lowerend of a pair of vertically sliding shafts 15 by means of links 16. Theupper ends of these slides Il carry an arcuate plate l1 which carriespins I3 adapted to coact with the arms of the clamp 33, as clearly shownin Figs. 5 and 13, in order to swing these arms toward each other inopposition to the spreading pressure normally exerted by a compressionspring 13. The inward movement of the clamp arms 33 is limited so thatthese arms may urge the hollow wire guiding fingers 33 of the spinningrotors 34 toward each other to a predetermined extent whereby thelingers 3| will definitely space the local zones of the advancing wires32 apart after the complementary pairs of wires have been spun ortwisted about each other in advance of these local zones. Whenever theplate 'Il is lowered and the clamps 39 are spread apart by the springs19. the spinner lingers 33 will also be spread apart by leaf springs 30coacting therewith, see Fig. l0. The cam C should be constructed so thatthe clamps 39 will become effective only when the fingers 33 aredisposed in the same horizontal plane, and after a predetermined numberof turns of the rotors 34 has been efiected, as indicated by the chartof Fig. 6.

The groove cam D, which actuates the spreaders 36 for retaining thesuccessive local zones of the pairs of advancing wires 32 in properlyspread condition for coaction with the feed fingers 42, 43, coaets withthe roller d oi' a lever Bi, which is swingably suspended from a pivotshaft 82, and the opposite swinging end of the lever 3| comprises an arm8|' secured to the shaft 32 and provided with a tooth 33 coacting with arecess at the lower ends of a pair of vertically movable slides 34 theupper end o! which carry an arcuate plate 85, see Figs. 7, 8 and 10. Thespreaders 36 are all mounted directly upon the vertically movablearcuate plate 35, and the movement of this plate is timed so as to causethe spreaders 3B to raise and to enter the successive spread andproperly spaced local zones between the pairs of wires 32 after the samehave been spun or twisted about each other in front oi' these localzones, and while the spinning lingers 33 of the adjacent rotors 34 areat rest and are being acted upon by the clamps 33. The timing of themovement of the spreaders 3B is likewise clearly indicated upon thechart of Fig. 6.

The sole remaining groove cam E which actuates the wire clamps 31 forlimiting he extent of twisting of the complementary pairs of wires 32 bythe spinning rotors 34, coacts with a roller e' carried by one end of alever 86 which is swingable upon the pivot shaft 32, and the oppositeswinging end of which is provided with a tooth 3l. The tooth 81 engagesa recess in the lower end of a vertically slidable shaft 38, the upperend of which carries an arcuate plate 33. The plate 39 is cooperablewith all of the wire clamps 31 so as to spread the jaws theerof inopposition to the action of springs 30 which normally tend to closethese jaws. as shown in Fig. 12, and the timing of the operation of theclamps 3l relative annees 9 to the adjacent spreaders It and spinningrotors 84 is also shown on the chart of Fig. 6.

While the punch and die actuating cams F and G, are next in order, itappears more desirable tonow speciiically describe the spinner or rotoractuating cams H and I, and other mechanism for revolving the rotors I4so as to twist the several pairs of wires on opposite sides ofsuccessive spread zones. 'I'he cams F, G. H, I diifer from the cams A.B, C. D. E. in that the latter are interna] or groove cams, while theformer are external or peripheral cams. As previously indicated. therotor actuating cams H. I are mounted upon the counter shaft l2. whichis rotated at half speed by the bevel gearing 50. so that the rotors Ilduring one cycle will revolve in one direction to twist. and durinar thenext cycle revolves in the opposite direction to again twist. thecomplementary pairs of wires 32 about each other. From Figs. '1, 8 and 9it will be apparent that one of the cams H. I coacts with one arm of abell-crank lever Il which is swingably suspended from a iixed stub shaftI2, and the other cam coacts with a roller I3 carried by the otherupwardly directed arm of the lever Il. This other arm 'of the lever 9ihas a winging extension Il which is connected to a rack N by means of alink 55; and the rack N is slidably suspended from a cover II andengages a pinion l1 secured to a shaft I which is Joumalled in the coverSi. The shaft 9e has a spur gear l! secured to an end thereof, and thisgear Il meshes with an annular series of teeth |00 formed on the medialportion of one of the spinning rotors 3l as shown ln Figs. 5, and i7, sothat oscillation of the lever 9| by the cams H. I, will cause thetoothed rotor il' to rotate four turns in a predetermined direction,twice during each cycle of operation. This rotary motion which isimparted to the rotor Il' by the gear Il, is imparted to the adjacentrotors 3l and from thence to all other rotors Il, by means of slightlybevelled coacting annular series of teeth lli formed on the rotors 3l,Il' and coacting with each other as indicated in Figs. 5, 10 and 17: andwhen the rotor 3l revolves. alternate rotors il of the series revolve inthe same direction, while the intermediate rotors revolve in theopposite direction. The spinner fingers IB which are pivotally suspendedfrom their carrying rotors Il, Il' and through which the wires l2 arefed, revolve with the rotors and are normally spread apart by thesprings BU as shown in Fig. lil. 'I'he timing of the rotation of therotors 3|. 34' relative to the other steps of the method. is alsoclearly indicated upon the chart of Fig. 6.

The punch and die actuating cams F, G, must cooperate perfectly with camA for moving the slides 4| in and out to feed the wires 32longitudinally, and with the cam B for moving the platen 5I and theslides Ii, up and down, in order that the wire advancing fingers I2. I3will not interfere with the down and up motion of the punches 3|! anddies 3|. As shown in Figs. 'l and 8, the cams F, G which are carried bythe counter shaft 49, coact respectively with rollers f. 9' carried bythe swinging ends of lever arms |82, lill secured to a pivot shaft IM.Another lever arm |05 which is an extension of lever arm |02, isconnected by means of a link Ille to a set of lower toggle links |01;while still another lever arm Nil which is secured to the outer end ofthe shaft |04 is connected by means of a connecting rod ill. bell cranklever and shaft assembly lili and link to a set of upper toggle links|I2,

see Figs. '1. B and 14. The lower toggle |01 is connected to a slide illmovable vertically along the frame 25 and which carries the lower diesIl. while the upper toggle ||2 is likewise connected to a slide illmovable vertically along the frame and from which the upper dies orpunches lt are suspended. and the reaction block IB for at least one ofthe toggles |01. ||2 should be made vertically adjustable relative tothe frame 2l as by means of an acuusting wedge ||1 movable with the aidof adjusting screws H8. as shown in Fig. i4. 'I'he punches til and thedies li will obviously be moved vertically and in opposite directions.when the cams F. G are being rotated by the shaft Il, and these camsshould be formed to produce the desired dwell and other action of thepunches and dies so as not to interfere with the movements of the slides4| and fingers l2. ll. The timing of the operation of the punches anddies is likewise clearly indicated by the chart of Fig. 6.

Became of the fact that the machine must be capable of simultaneouslyattaching twenty insulated wires I2 to the closely adjacent terminalsill of each of the successive cards 40, each comprising tencomplementary pairs of terminals Il! arranged in layers and separated bysheets |20 of insulation, as shown in Fig. 26, the punches II and dies3| must necessarily be small yet extremely strong and durable, see Figs.10, 14, 15, i7, and 19 to 25. inclusive. Each individual punch Il isadapted to cooperate with a pair of complementary wires I2 and terminals||il as the successive spread zones of the wires I2 after having beentwisted about each other on opposite sides of each sone by the rollersIl. have been picked up by the corresponding sets of lingers 42, Il andadvanced to the zone of action of the dies. The attachment of thetransfer fingers l2. I3 to their carrier slides 4| must be such that theadjacent sets of these lingers 42, Il can spread out as each slide 4|travels its own radial path, and since the fingers l2. remain in forwardposition while the wires 32 are actually being clamped to the terminals|19 by the punches lli and dies 3| the movable punches and dies must beadapted to pass between the front and rear pick up fingers I2. I3, seeFig. 1i). 'Ihe complementary sets of fingers 42, Il are thereforesuspended from their respective carrying slides Ii by means of U- shapedplates |2| which clear over each other and some of which are longer thanothers as shown in Fig. 18. There are ve sets of these relativelyslidable finger suspension plates |2I on each side of the verticalcentral plane of the machine, and each slide 4| is provided with apositioning bushing |22 which is cooperable with an adjacent verticallymovable positioning pin 23 can'ied by the lower die supporting slideill. see Figs. 10, 14 and 18. 'I'he pins |23 are also adapted to passthrough a series of openings in a stationary stripper plate |24, and thelower slide ill, besides supporting the dies lll. also carries threeparallel upright front positioning pins |25 shown in Figs. 5, 10, 14 and15 which are cooperable with the central and two outer openings t28 inthe successive cards In so as to accurately position the terminals litwhile the wires 82 are being attached thereto. and to also lift thecards from their transfer pins |21 carried by the card supply table 21and which normally coact with the two intermediate openings |26 of thecards 40, see Figs. 14 and 1'1.

The lower dies are clamped as an arcuate se- 15 ries in the slide Il asshown in Fig. 5. and may be individually adjusted by means of set screws|25 coacting therewith, see Fig. l5. The upper dies or punches 30 aresecured in a similar manner to the upper slide |I5, and these punchesmay also be individually adjusted by means of set screws |20, and hooks|30 coacting therewith: and each of the punches 30 is also provided witha set of opposed strippers |3I as shown in Figs. 10, 15 and 23. Theesstrippers I3I. which force the wires 32 along the fingers 42. 43 andinto the terminals ||5 before the punches act, are slidably mounted ingrooves in the punches 30, and are engaged by fingers |32 secured to thefront stripper retainer |33 which is urged downwardly by a compressionspring |34 coacting with a plunger |35 so that when the punches 30 arelifted away from the lower dies 3 I, the strippers |3| will movedownwardly to the position indicated in Fig. l5. The punches 30 and dies3| are preferably guided for vertical movement by parallel rods 55'coacting with the slides I|3. ||5; and are adapted to coact with eachother in the narrow arcuate none between the fingers 42, 43 as indicatedin Figs. l0 and 18: and each punch 30 has upper and lower recesses |35,|31 which are cooperable with upper and lower sockets |35. |30.respectively, of the complementary die 3| so as to simultaneously clampthe terminals |I of superimposed layers to the adjacent pair of wires32, see Fig. 25.

The mechanism for feeding or supplying the successive cards 40 eachcomprising two layers of terminals H0 separated by a stiff sheet |20 ofinsulation, to the zone of action of the punches and dies as shown inFigs. 1. 2. 5, 14. 27 and 28, and comprises a table 21. an annular rotoror member |40 rotatably mounted upon the table 21 and having an annularseries of pads |4| each provided 'with two of the card advancing pins|21. a horizontally and vertically movable plate |42 cooperable with thepositioning pins |25 of the lower die slide I I3 to assist the pins |25in transferring the cards 40 and to strip or remove the completed wireand card assemblages from these pins, the gearing operable by the driveshaft 41 to index the member |40 and to actuate the plate |42. The

table 21 is pivotally suspended from the front of r the main frame 25 bymeans of an upright hinge pin |43 so as to permit the table 21 to beswung out of normal position as shown in Fig. 2; and the drive shaft 41which is an extension of the main drive shaft 45, is connected with avertical shaft |44 journalled in the table 21, through reduction gearingconfined within a gear box |45 and through a removable coupling |45, seeFig. 2'1. The shaft |44 is connected by spur gears |41. |48 to a countershaft |40 which is journalled in the rotary member |40 but is also freeto rotate relative to the table 21; and the counter shaft |49 coactsthrough Geneva gearing |50 with a pinion journalled on a fixed stubshaft |52 and coacting with an internal annular or ring gear |53 whichis secured to the card feed rotor or member |40. A rotary cam |59attached to the shaft |40 has a cam groove K which cooperates with alever attached to an oscillatory pivot shaft |54 mounted upon the table21, and this shaft |54 carries an arm |55 which is connected to thestripper plate |42 by means of a' connecting rod |55 coacting with alever |51 and coasting with another arm |55 to produce swinging movementof the plate |42. 'Ihe card feed assemblage is obviously so constructed,that when the drive shaft 41 is being continuously rotated. the cardtransporting member |40 will be intermittently revolved by the Genevagearing |50 by steps equal to the distance between centers of thesuccessive pads I4|.\and the stripper plate |42 will be actuated duringeach successive advancement of the rotor |40 so as to press the cards 40onto the pins |25 and to thereafter remove the attached cards 40 fromthe positioning pins |25. From the chart of Fig. 5, it will be notedthat each interval of intermittent rotation of the member |45 consumesthree seconds, and the successive cards 40 may be positioned upon theconveying pins 31 of the advancing pads |4| by one or more attendantsstationed about the table 21.

The final assembly discharge conveyor 2l is mounted upon the table 21above and independently of the rotor member |40, and in approximatelyhorizontal allnement with a plate |55 extending rearwardly from thestripper plate 42. by means of rollers |50, |5| of which the roller |5|is positively rotated by means of a chain drive |52. see Figs. 5 and 27.This chain drive |52 is constantly operated from a horizontal shaft |53which is Journalled on the table 21 and is connected to the verticalcentral shaft |45 by means of bevel gearing |54, and the tension of theendless conveyor 23 may be adjusted with the aid of tensioning screws|55. An ironing roll |55 may also be provided above the conveyor belt asillustrated in Figs. 1, 2 and 5; and the conveyor 23 is adapted todeliver the wire and card assemblages from the machine in the mannerdepicted in Fig. l with the wires 32 disposed approximately parallel toeach other and the corresponding terminals of the successive equallyspaced cards 4| firmly clamped to the same wires 32 of the series. Themachine should also be provided with a suitable control switch |51preferably mounted upon the main frame 25 near the card supply andassembly discharge table 21.

During normal operation of the improved machine while carrying oncommercial exploitation of the improved card wiring method, one or moreattendants should be stationed about the card supply table 21 in ordert0 apply card assemblages 40 to the conveying pins |21 of the successivepads |4I, and the reels 25 should all be provided with abundant suppliesof insulated wire 32, whereupon operation of the rotor 25 by actuationof the switch |51 will set all of the mechanisms in motion. Thesuccessive steps of the method will then be carried on automatically asdepicted in the diagrams of Figs. 29 to 35, inclusive, and thecorresponding locations of the various operating elements are indicatedby degrees on the chart of Fig. 6, it being understood that eachcomplete cycle of operation is represented by 360 on the chart.

The diagram of Fig. 29 shows the relative location of the operatingelements at 50 from the starting point of Fig. 6. The stripper |42 hasbeen Withdrawn, and this withdrawal has permltted the lower dies 3| andlocating pins |25 to move upwardly with the card 40, into the positionshown, and the upper punch 30 and lower die 3| are acting in crimp thewires 32 into the terminal sockets of the card 40. The slide 4| with itslingers 42, 45. is holding and guiding the wires 32 into the terminalsockets. and the complementary Wires 32 of each pair have been spun onopposite sides of the zone of attachment to the terminals. The clamp 31is clamping the wires 32 in preparation for the next spinning operation.

'I'he diagram of Fig. 30 shows the relative location of the operatingelements at from the starting point of Fig. 6. The stripper |42 has justmoved inwardly underneath the card M, the punch 30 and die 3l areseparating, and the card lil, with the wires 32 attached thereto, isbeing stripped from the die 3|. The slide li is rising so as to clearthe wires for its return trip, and the wire clamp 31 is still holdingthe wires 32 so as to limit the extent of twisting cr spinning. Thespinner fingers 38 have just started to spin the next section of thecomplementary wires of each pair.

The diagram of Fig. 3l shows the relative location of the operatingelements at 112 from the starting point in Fig. 6. The spinner lingers3B have partially completed the spinning operation which was commencedin Fig. 30, the punch 3l) and die 3| have separated completely. and theslides 4| are fully elevated and ready to start on their return trip inorder to pick up the next zone of separation between the wires 32.

The diagram of Fig. 32 shows the relative location of the operatingelements at 150 from the starting point of Fig. 6. Here the spinnerlingers 2B have completed the spinning operation of the wires 32 whichwas started in Fig. 30. the separating fingers 36 have moved upwardlybetween the complementary wires 32 of each pair while they were heldapart by the fingers 38, and the lingers 38 are now ready to bring thecomplementary wires of each pair inwardly around the fingers 3B. Theslides 4| have moved away from the dies and are now disposed directlyabove the fingers 36.

The diagram of Fig. 33 shows the relative location of the operatingelements at from 190 to 198 from the starting point of Fig. 6. Theslides 4| have now descended and the fingers 2, I3 of each set haveclamped the adjacent pair of wires 32, straddling the section of thewires which are to be crimped into the terminal sockets of thefnextterminal cards Ill. The wire clamp 31 has been shifted downwardly toclear the forward path oi' travel of the slide 4| and lingers I2, 43,and the separating lingers 36 are ready to move downwardly for the samereason.

The diagram of Fig. 34 shows the relative location of the operatingelements at 29|) from the starting point of Fig. 6. The separatingiingers IB have been moved downwardly, and the slides Il and lingers l2,43 have advanced part way toward the dies, and the spinner fingers 38are acting to spin the wires 32 during the rst part of this advancementof the slides 4|. The card stripper |42 has moved away from the diessuiiiciently to clear the indexing mechanism of the card supply table21, and this supply table is indexing and bringing another card 40 intoposition directly over the lower die 3l.

The diagram of Fig. 35 shows the relative location of the operatingelements at 340 from the starting point in Fig. 6. In this iinal diagramthe indexing operation oi the card supply table 21 has been completed,and the stripper |42 has moved inwardly over the card 40 to hold thesame down, while the punch 30 and die 3| have moved partially towardeach other thereby causing the positioning dowels |25 to be pressed intothe positioning holes |26 o! the card #il which is about to be attachedto the wires 32. The spinning of the advancing wires has been completedand the slide 4| is approaching its final position under the punch 30.

Following the operation illustrated in Fig. 35, the operation of Fig. 29is again performed and the several steps depicted in the diagrams arethereafter automatically repeated to produce the successive cycles ofoperation disclosed in the diagram of Fig. 6. When the successive cardsl0 are attached to the longitudinally advancing wires 32. they aredelivered over the final conveyor 28, and the wires 32 may besubsequently severed into suitable lengths having the desired number ofcards l0 associated therewith.

It will thus be noted that the successive cards 60 are rapidly andeffectively attached to the several pairs of wires 32 with each wirefirmly secured to the corresponding terminals of the successive cards4l), and the punches 30 and dies 3| are so formed that they will clampthe terminals IIS to the insulated wires and will drive the small teethof the terminals shown in Fig. 26, through the insulation so as toproduce effective electrical connections. While the wires are attachedto the cards d0 radially, the adjacent wires of the final assemblagesare disposed approximately parallel to each other and the correspondingterminals of the successive cards dii are eliectively connected inseries with each other. When a number of the card and wire assemblageshave been produced and the wires have been cut into suitable lengths,the corresponding cards of the several assemblages may be grouped intostacks with two or more cards in each stack, and the several stacks maybe disposed laterally adjacent to each other and may be caused tocooperate with the brushes in the usual manner. The iinal systems willthen have a plurality of stacks disposed laterally adjacent to eachother. and the corresponding terminals of the successive stacks will beconnected in series by the wires 32 and each zone of attachment of thesame pairs of wires will have the complementary wires 32 of each pairspun about each other on opposite sides of the point of attachment, thusproducing an ideal system devoid of faulty connections and oiundesirable electrical disturbances.

The spinning of the pairs of wires on opposite sides of the point ofattachment to the terminals is primarily accomplished by movements ofthe rack 94' which in one cycle of the machine, that is, a cycle whicheiects the clinching. of a set of terminals to a set of wires, moveseither to the right or to the left, as viewed in Fig. 9 and on thesucceeding cycle of the machine will move in the opposite direction,that is, either the left or the right. When the apparatus is started,four twists are made in each set of wires between the supply reels 26and a spinning rotor 34 before the wires are passed through the spinnerlingers 38. This twist is in such a direction that when the rack 84moves from its original location in one direction, it will untwist thosefour twists, stop momentarily while the wires are drawn part-way forwardtoward the terminals, and then the rack 94 will continue to move in thesame direction to the end of its travel to make four twists in the wiresbetween the rotors 34 and the supply reels 26. The clinching operationwill then take place. The feed lingers 42 and 43 will be retracted, 'andthe rack 94 will be moved half way to its ultimate position. Thismovement of the rack 94 will untwist the four twists just put into thewires between the spinner fingers 38 and the supply reels, and aiterhesitating for a short time the rack 94 will continue its movement backto its original position to put four twists into the wires between thespinner fingers 3B and the supply reels. Thus. in the operation of themachine the wires are twisted between the previously attached terminaland the spinner lingers 3B eight times in one direction, this twistingbeing effected in two steps and the twists being applied between theclinched terminals and the spinner fingers I8. Thus. in a complete cycleof the apparatus the spinning rotors 34 in spinning four times twist theincoming wires four times between the supply reels and the spinnerfingers 38 and then when rotating in the opposite direction the spinningrotors Il turn eight times to take out the four twists originally putin, and put in four twists in the opposite direction.

From the foregoing detailed description it will be apparent that mypresent invention provides a simple but highly effective method ofattaching layers of terminals or the like to successive prtions of aplurality of elongated elements such as wires or the like, and oftwisting complementary pairs of the wires on opposite sides of the zonesof attachment. The invention furthermore provides simple, highlyeilicient and durable mechanism for effecting commercial exploitation ofthe improved method in an automatic and dependable manner. The improvedmethod and apparatus have proven very satisfactory and successful inactual commercial use, especially as applied to the attachment oftelephone terminal cards to insulated wires, and while the apparatus mayappear quite complex in view of the relatively delicate and compactconstruction oi' the terminal cards and wires which are handled inconnection with such work, the improved apparatus has neverthelessvastly reduced the amount of labor involved in producing such telephoneequipment. Because of the rather complicated nature of the machine, ithas been deemed desirable to show some parts thereof ratherdiagrammatically in order to clarify the disclosure, but it will beapparent, from the chart oi' Fig. 6 and from the diagrams of Figs. 29 to35, inclusive. that the improved machine is adapted to methodically andeilectively perform the several steps o! the method expeditiously and ina minimum period of time.

It should be understood that it is not desired to limit this inventionto the exact steps of the method, or to the precise construction of theapparatus, herein shown and described, for various modincations withinthe scope of the claims may occur to persons skilled in the art What isclaimed is:

l. In a mechanism for attaching terminals to wires, means forintermittently advancing a plurality of pairs of wires longitudinally indefinite paths toward a common zone, means for successively twistingshort lengths of each pair of wires about each other as they approachsaid zone to provide spaced twists along said wires, means for spacingthe lengths of wires intermediate said twists in predetermined positionswhereby each wire occupies the same position after each successiveadvance, means for successively positioning a performed group ofterminals adjacent the wires in said zone, means for attaching eachterminal of the group to its adjacent wire, and means for coordinatingthe movement of the aforementioned means for successive operation.

2. In a mechanism for attaching terminals to wires, means forintermittently advancing a plurality oi wires longitudinally toward acommon zone, means for successively twisting relatively short lengths oiadjacent pairs of said wires about each other as they approach said zoneto provide spaced twists along the wires. means for spreading andseparating the wires of each pair between successive twists, means forsuccessively positioning preformed groups oi' terminals adjacent to theseparated portions of the wires at said zone, means for attaching eachterminal of the group to its adjacent wire, and means of coordinatingthe movement of all of said means for successive operation.

3. In a mechanism for attaching terminals to wires, means forintermittently advancing a plurality of pairs of wires longitudinally indefinite paths toward a common zone, means for successively twistingshort lengths of each pair of wires about each other as they approachsaid zone to provide spaced twists along said wires, means for spacingthe lengths of wires intermediate said twists in predetermined positionswhereby each wire occupies the same position after each successiveadvance, means for intermittently positioning successive preformedarcuate groups of terminals adjacent the spaced portions of the wires insaid zone, means for attaching each terminal of each group to itsadjacent wire so as to provide electrical connections. and means forcoordinating the movements of all of said means for successiveoperation.

4. In a mechanism for attaching terminals to wires, means forintermittently advancing a plurality of wires longitudinally toward acommon zone, means for successively twisting relatively short lengths ofadjacent pairs of said wires about each other as they approach said zoneto provide spaced twists along the wires. means for spreading andseparating the wires of each pair between successive twists. means forintermittently positioning successive preformed arcuate groups ofterminals adjacent to the separated portions of the wires at said zone,means for attaching each terminal of each group to its adjacent wirebetween successive twists, and means for coordinating the movements ofall of said means for successive operations.

5. In a mechanism for attaching terminals to wires, means forlongitudinally advancing a plurality of wires toward a common zone,means for twisting relatively short lengths of adjacent pairs of saidwires about each other as they approach said zone to provide successivetwists spaced along the wires, means for spreading and separatinglaterally adjacent portions of the wires of each pair between successivetwists. means for successively postioning a preformed group of terminalsadjacent said spread portions of said pairs while at said zone, meansfor atta/ching each terminal of the group to its adjacent wire portion,and means for coordinating the movements of all of said means forsuccessive operations.

6. An apparatus for attaching wires at longitudinally spaced points tothe terminals on successive insulator cards comprising means forattaching a plurality of wires to spaced terminals on a card, means forintertwisting pairs of said wires in a zone following the attachment ofthe wires to the terminals of a card, means for spacing the wires atpoints where terminals are to be attached following a twisted zone, andmeans for grasping the wires at the spaced points and advancing them tothe attaching means for attachment to the next card.

'1. An apparatus for attaching wires at longitudinally spaced points tothe terminals on successive insulator cards comprising means forattaching a plurality of wires to spaced terminals on a card, twistingmeans for intertwsting said wires in pairs after being attached to thetermi-

